Router 2600 Pro Operator Manual

Router 2600 Pro
CNC Machine
User’s Manual
approved
http://www.denford.co.uk
1
Router 2600 Pro Operator Manual Page 1
1: Contact Information
Address: Denford Limited,
Armytage Road,
Brighouse,
West Yorkshire,
HD6 1QF,
UK.
Telephone: General Enquiries 01484 728000

Fax: 01484 728100
E-mail: For sales enquiries contact, sales@denford.co.uk
For machine servicing enquiries contact, service@denford.co.uk
For customer services, contact customerservices@denford.co.uk
Technical Support: Visit Denford Technical Forum at www.denfordata.com/bb
Telephone Denford Customer Services: 01484 728000

E-mail: customerservices@denford.co.uk
Monday to Friday 8.30am - 4.30pm GMT
1: Notes

1 : Notes

1: Contents
Contents Page
1: Contact Information .............................................................................................2
1: Notes ...................................................................................................................2
1: Contents ..............................................................................................................4
1: Warning Notices ..................................................................................................5
1: About this Manual ................................................................................................9
1: Introducing your Router 2600 Pro .......................................................................10
1: Before Beginning to Setup...................................................................................11
2: Safety Features Overview and Precautions ........................................................12
2: Safety Features - Emergency Stop Button ..........................................................13
2: Safety Features - Interlock Guard Switch ............................................................14
2: Dust Extraction & General Dust Precautions.......................................................15
3: Unpacking and Lifting your CNC Machine...........................................................16
3: Choosing a Site for your CNC Machine...............................................................17
3: Removing Protective Coatings and Packaging ...................................................18
4: Switching the Router On......................................................................................19
4: Switching the Router Off......................................................................................20
4: Homing the Machine Axes (Home Mode) ............................................................21
4: Manual Control - Axis Definitions (Jog Mode) .....................................................22
4: Front Machine Operators Panel .........................................................................23
5: Performing a Tool Change ...................................................................................24
5: Setting Tools in the Router Motor ........................................................................27
6: Automatic Tool Change Option ............................................................................28
7: Using the Work Clamp and Datum Plate .............................................................33
8: Large Format Vacuum Bed Option ......................................................................37
9: Planning Procedure for Maintenance Work .........................................................40
9: Maintenance Schedule ........................................................................................41
9: Maintenance of the Spindle Motor .....................................................................42
9: Cleaning the Microswitches .................................................................................42
9: Lubrication of the Slideways and Leadscrews.....................................................43
9: Maintenance Log .................................................................................................44
10: Technical Support ..............................................................................................46
11: Specification ......................................................................................................47
11: EC Declaration of Conformity for Machines Prior to 29.12.09 ...........................48
11: EC Declaration of Conformity for Machines After 29.12.09 ...............................49
11: Router 2600 Pro Noise Level Test Results ........................................................50
12: Glossary ............................................................................................................51
13: Notes .................................................................................................................54

1: Warning Notices
Warranty Disclaimer.
The Warranty on your Router will be invalidated if any modifications are made to the machine
or any additional ancillary equipment fitted, or any adjustments are made to the controlling
devices without prior notification from Denford Limited. Please refer to the information held in
your separate Warranty pack, for specific details.
Maintenance Disclaimer.
Always obtain permission from the person responsible for machinery in your establishment,
before accessing the electrical control panel or Router machine casings to carry out any
maintenance work. All work must be carried out by personnel suitably qualified for each
maintenance task, to avoid damage to the machine systems and injury to the maintenance
personnel. Denford Limited cannot accept responsibility for any damage, injury and/or loss
that may occur through incorrect maintenance of your router.
Use of Machine.
Your Router is designed for machining hard and soft woods, certain ceramics, plastics and
non-ferrous metals. In each case, the appropriate tooling, speeds and feeds should be used
as recommended by the material supplier. Information should also be sought from suppliers
regarding the safety specification of the materials to be cut. Facility is provided for connecting
a vacuum system for dust extraction. Always use the machine coupled to such a system.
Your Router is not intended for use with any ferrous metals.
Do not remove the router head and attempt to use it independently of the machine.
Do not machine any toxic, radio-active or volatile materials.
Use of the machine for any purpose other than those for which it is
designed may result in injury, and may also invalidate the warranty.
The machine should only be used under constant supervision, to help guard against, and
respond to, any unforeseen hazard such as fire or explosion. First aid and firefighting
equipment (CO2 Extinguisher) should be located nearby in a clearly signed and prominent
position.

1: Warning Notices
Sound Level Disclaimer.
The Noise Level test published in this manual is for the machine and any essential equipment
such as dust extraction equipment, and complies with the relevant standards. It cannot make
provision for noise resulting from the cutting process, since this is a variable, depending on
such factors as material, cutting data and tooling.
Any ancillary equipment supplied by Denford will also comply with the relevant standards.
However, when used jointly with the machine in a machining environment, the combined sound
levels emitted may require that Personal Protection Equipment, such as ear defenders, be
used. Other factors, such as high ambient noise levels and nearby machinery and equipment
can also increase the sound levels.
It may be possible to reduce the sound levels by changing the machining process and/or repo-
sitioning the machine and/or its ancillary equipment.
If, under these circumstances, it is felt that the sound level is still unacceptably high, then
independent advice should be sought and complied with.
If you have any doubts and/or questions regarding the use, specification, servicing, or features
of your machine, please contact Denford Customer Services.
Denford Limited reserves the right to change the specification and/or operating features
regarding this CNC machine without notice or documentation.
Portable Appliance Testing.

This machine has an Inverter drive fitted with Internal EMC filters.
The Insulation Resistance test should not be carried out with the filter in
circuit.
If the test is carried out with the filter in circuit then the appliance will
fail the Insulation Resistance Test and damage can be caused to the
machine.
In-Service Testing
This is the testing carried out as a routine to determine whether the equipment is in a
satisfactory condition.
In-Service testing will involve the following:
• Preliminary inspection
• Earth continuity tests (for Class 1 equipment)
• Insulation testing (for Class 1 equipment)

1: Warning Notices
Portable Appliance Testing (continued).
Electrical testing should be performed by a person who is competent in the safe use of the
test equipment and who knows how to interpret the test results obtained. This person must
be capable of inspecting the equipment and, where necessary, dismantling it to check the
cable connections.
If equipment is permanently connected to the fixed installation, e.g. by a flex outlet or

other accessory, the accessory will need to be detached from its box or enclosure so that
the connections can be inspected. Such work should only be carried out by a competent
person.
Preliminary inspection
Formal visual inspections should only be carried out by persons competent to do so.
• Cables located so as to avoid damage

• Means of disconnection/isolation readily accessible
• Equipment positioned to avoid strain on cord
• Equipment is being operated with the covers in place
• Indiscriminate use of multi-way adaptors and trailing sockets is avoided
• Identify signs of overheating
• Identify signs of damage to insulation
• Check the correct size fuse is fitted (13A)
• Check the flexible cable connections and anchorage.
Before carrying out the following tests ensure the machine is

disconnected from any external equipment or supplies.
Ensure USB and RS232 connections are removed prior to testing.
Earth continuity Test (Class 1 equipment)
The test should be carried out at 25A for a period of 5 – 10 Seconds

The reading should be less than 0.1 + R (where R is the resistance of the lead)

1: Warning Notices
Portable Appliance Testing (continued).
Insulation Resistance Test (Class 1 equipment)
A qualified electrical engineer should make the following

modifications before carrying out the Insulation Test.
• Remove the cover from the electrical panel.
• Locate the Spindle drive and remove the EMC and VAR screws.
The insulation resistance test can now be carried out
The applied test voltage connected between Live/Neutral and Earth should be 500VDC
The insulation Resistance should be greater than 1M Ohms
The EMC and VAR screws must be refitted prior to operating the machine again.

1: About this Manual
Using this manual This manual provides information describing how to transport, site,
setup and operate the basic functions of your Denford Router CNC
machine, including any operational features of hardware specific to
the Denford Router series.
This manual does not provide any information regarding the
software packages used. Please refer to the help section within the
appropriate software.
Please note that the Electrical Diagrams for your Router are not
included in this manual - they are delivered separately in the
standard equipment box supplied with your CNC machine.
If you have any doubts and/or questions regarding the specification,
servicing, or features of your Router, please contact Denford
Customer Services. Denford Limited reserves the right to change
the specification and/or operating features regarding this CNC
machine without notice or documentation.
Disclaimer Please note that due to the nature of hardware and software
developments, the specifications and features of this product can
change without notice. The information contained in this manual is
correct at the date of printing only - August 2010. No liability can
be accepted by Denford Limited for loss, damage or injury caused
by any errors in, or omissions from, the information supplied in this
manual.
Screenshots Please note that any screenshots are used for explanation purposes
only. Any numbers, wording, window or button positions may be
different for the configuration of the CNC machine control software
being used to control your Router.
Language This manual is written using European English.
Contact Any comments regarding this manual should be marked for the
attention of our technical authoring team and referred to the
following e-mail address: customerservices@denford.co.uk

1: Introducing your Router 2600 Pro
Congratulations on your purchase of a Router 2600 Pro CNC machine. In this manual you
will learn how to setup and use your Machine correctly and safely.
Your Router is a full three axes CNC router with a large work area, allowing machining of
materials approaching 600 x 400mm in size. Suitable for all levels of education and training,
it is manufactured to meet industrial standards. Together with rapid traverse rates of up to
5000 mm/min your Router is the ideal partner for intensive 3D applications, such as the
F1 in Schools Formula One Technology Challenge (www.f1inschools.co.uk) and the 4x4 in
Schools Technology Challenge. Your Router 2600 Pro is designed with you in mind - making
the processes involved both safe and easy to use.
Main Features:
• Designed specifically for Education and Training.
• Manufactured to industrial standards.
• Programming via International Standards Organisation format, incorporating controls
such as FANUC.
• CE approved for safety.
• Capable of cutting common resistant and prototyping materials, including Wood, MDF,
Wax, Plastics and Acrylics and non-ferrous metals.
• Links to various CAD/CAM software packages.
• Totally enclosed high visibility interlocked guard.
• Feedrate and Spindle Speed override controls.
• Dust extraction ready.

1: Before Beginning to Setup
Before beginning to set up your Router 2600 Pro, please check your separate
order documentation, making sure that all items have been delivered to your
establishment. Any missing or damaged items should be reported to Denford
Customer Services as soon as possible.
The following equipment is supplied as standard with your Router CNC machine :
• Router 2600 Pro CNC machine. Note that the precise specification of your CNC
machine will depend on any options selected at the time of ordering (see below).
• 1 x Set of Workholding Clamps
• 6/7mm Collet and 12/13mm Collet
• 1 x Allen (hex) keys pack.
• 2 x Special Double Ended Spanners for tool changing.
• External USB Cable
• 1/4”Dia. Ball Nose Cutter
• 1 x Router 2600 Pro warranty pack (UK Machines only)
• 1 x CD-ROM containing Denford VR CNC Machine Control Software and
manuals, and Machine user’s manual.
• 1 x VR CNC Machine Control Software Security Key (dongle) or Flash screen
software (supplied on removeable media).
The following optional equipment may also be supplied with, or ordered for, your
machine:
• Additional Software: CAD/CAM, Offline CNC Machine Control.
• CNC Machine Control software security keys (dongles) or licence disks.
• Machine work bench and PC workstation.
• Vacuum for dust collection.
• Additional work holding systems.
• Various tooling packages.
• On-screen representation of industrial control systems (FANUC 21i) and optional
link to industrial keypad.
• Courseware, project books and project material packages.
• Video conferencing system.

2: Safety Features Overview and Precautions
Safety Features Overview.
The following safety features are standard on your Machine:-
• Emergency stop button.
• Manually operated, totally enclosed guard door with interlock switch.
• Option on control software to check CNC programs using toolpath graphics, prior to machining.
• Automatic tool retraction and spindle stop for tool changing.
Safety Precautions.
Safety is very important when working with all forms of machinery but particularly when working
with CNC equipment, due to the hazardous voltages, speeds and forces that exist in the
hardware. Follow the rules below at all times, when using your machine.
General Safety Precautions :
• Wear clothing suitable for machine operation and follow the safe working procedures in
place at your establishment. When emptying the dust extraction system base unit or cleaning
down the machine, wear suitable respiratory protective equipment that is CE marked. Other
personal protective equipment, such as eye protection, overalls and gloves should also be
considered.
• Do not place any objects so that they interfere with the guards or the operation of the machine.
• Never try to clean the machine if any part of it is rotating or in motion.
• Always secure the work on the table or in a fixture or vice.
• Ensure that the correct cable for the power source is used.
• Ensure the mains power is switched off (and preferably unplugged) before starting any
maintenance work on the machine. Depending on ancillary equipment supplied with machine
there may be more than one power supply to the machine. When isolating machine always
ensure that all power sources have been disconnected. Post a notice informing others not to
use the machine since it is undergoing maintenance.
• Hazardous voltages can still exist immediately after switching the machine off. Always wait at
least 5 minutes before accessing the CNC machine electronics.
• If power fails turn off the mains power switch immediately and unplug the machine from the
mains power socket.
• Correct maintenance is an essential part of the safe use of this machine (see the Maintenance
section for further details).
• Observe caution when handling machine tooling, particularly with regard to hot and/or sharp
cutters. Consider wearing protective gloves.
• When an emergency stop is required, press the circular red emergency stop button, located on
the right side of the CNC machine front panel.
• If laser scanner fitted do not stare into laser beam. Refer to Scanner instruction manual for all
aspects of safe use of laser.
• Visually check door and window for signs of cracks or chips. Any damage should be reported
immediately to Denford and a suitable replacement obtained without delay.
• Regularly check door gas springs and/or hinges for correct operation and inform Denford of
any deterioration.
2: Safety Features - Emergency Stop Button
The emergency stop button is

located on the right front panel of
the CNC machine. To activate an
emergency stop, press the button
fully in until it clicks.
A circular, red emergency stop button is located on the right front panel of your Router,
as shown above. When pressed, it has the effect of stopping all axes and spindle
movements immediately. The guard interlock switch will also close. When the safety
guard door is in its closed position, this will prevent access to the working area of the CNC
machine.
To activate an emergency stop, press the button in until it clicks. The emergency stop
button will continue to cut all power to the machine drives and continue to keep the
interlock switch closed, until the release sequence is performed.
To release a closed emergency stop button, push in and turn the button clockwise until it
springs back out.
After releasing an emergency stop, you may need to reset any CNC control software
messages and home the CNC machines axes.
Check the emergency stop button is released before attempting to power up the Router

2: Safety Features - Interlock Guard Switch
Note - x An interlock guard switch is fitted to the front machine door. The
A closed safety guard switch unit itself is attached behind the lower machine panel,
door cannot be opened accessible from beneath the front of the machine. The lock must be
when:
• The machine is manually released to enter the working area when the 24 volt circuit
switched off (ie, not in has failed and the door is clamped electrically. An override facility
use). To release the is provided on the interlock guard switch, allowing temporary
interlock guard switch,
supply power to the removal of the guard lock feature. For manual interlock release, the
machine. power supply must be switched off.
• The emergency stop
button is fully pressed
in. To release the lock,
push in and turn the Left: The interlock guard
emergency stop button switch unit (circled) is
counter-clockwise until located behind the lower
it springs back out to front machine panel.
its ready position.
• Machining is taking
place. The interlock
guard switch will
release when the
machining operations
have been completed 1) Working beneath the front edge of the machine, locate the
and the machine interlock guard switch unit.
controlling software is
operating in Jog Mode. 2) Using a small flat or crosshead screwdriver, loosen the manual
override locking screw until the circular black plastic lock screw
Warning - x can be turned (refer to photograph below).
3) Using a 3mm allen key, turn the circular black plastic lock
Danger of serious injury! screw one quarter turn to switch off the guard lock feature. If in
Do not let unauthorised doubt refer to the lock/unlock symbols embossed on the casing
personnel use the
machine when the guard surface.
lock feature is disabled. 4) If necessary, tighten the manual override locking screw slightly.
Ensure the guard lock
feature is switched back If you need to leave the machine, post a warning note informing
on as soon as possible. users that the safety guard door lock is not operating.
Under no circumstances
must the safety switch
actuator be removed (or unlocked Left: Looking directly at
marker
a spare or replacement the face of the interlock
actuator, or other device guard switch unit.
be used) to defeat manual locked
override
the safety interlocking locking triangular lock
marker
system. screw screw position

marker
unlocked
marker

2: Dust Extraction & General Dust Precautions
If cutting known hazardous materials, the machine must be used
with a suitable dust extraction system fitted and enabled.
Your Router is designed to run with a dust extraction system, used to remove any
potentially harmful airborne dust particles from within the working area of the machine.
Denford can supply dust extraction systems for your machine, or you may wish to
connect your own system.
Connect the pipe from your dust extraction system through hole in the left hand cabinet
wall to the hole on the left hand side of the spindle motor adaptor plate.
It is a legal requirement to have the dust extraction system
independently tested every 14 months to ensure that dust is kept
General Dust Safety Precautions.
Obtain "material safety data sheets" from your material suppliers and enforce the
recommended precautions. Be aware that certain hardwood and other material dust
particles, such as oak and MDF, could contain known carcinogens. Please consult
your materials supplier for further details.
Dust particles that remain inside the working area of the Router after a part has been
machined, should be removed using a vacuum.
Never used a compressed airline for this purpose.
When emptying the dust extraction system base unit or cleaning down the machine,
wear suitable respiratory protective equipment that is CE marked. Other personal
protective equipment, such as eye protection, overalls and gloves should also be
considered.
Dust particles on the floor can cause slipping. This should be monitored by the
operator and removed before becoming a hazard.
Launder overalls regularly, provide good washing facilities with hot and cold water,
soap and towels and encourage a high standard of personal hygiene.
Failure to fit and enable a suitable dust extraction system when
machining known hazardous materials, and failure to adhere to
the material safety data sheets, could lead to the following health
problems which are among the potential effects associated with
exposure to certain dust particles:
• Skin disorders.
• Obstruction to the nose.
• Rhinitis.
• Asthma.
• Nasal cancer.
3: Unpacking and Lifting your CNC Machine
If your CNC machine has been supplied inside a delivery box, cut the
Warning - x top of the box open and remove any packaging carefully. To obtain
better access to the machine, remove all the sides from the delivery box.
Your Router 2600 Pro weighs 160 kg. for bench mounting: with floor
Caution.
Always use sensible
standing unit it weighs 275 kg.
lifting precautions in With the bench mounting unit a suitable method of transportation must
accordance with Health be used as the unit is not fitted with wheels: for example secure machine
and Safety Regulations
on a pallet and transport using a pallet truck.
in your establishment.
If lifting by crane, suitable certified slings must be used as shown in
following the illustration.
Denford do not advise manual lifting of this machine, however if no other

suitable alternatives are available, the machine only could be lifted by at
least 4 people, one at each corner. Account should be taken of the non-
uniform distribution of the weight of the machine. It is generally heavier at
the right hand end than the left hand end. The use of suitably rated lifting
bars through the hollow sections under the machine may assist in lifting the
machine.
Always use sensible lifting precautions in accordance with Health and
Safety Regulations in your establishment. Particularly in the case of manual
lifting be aware of the danger of trapping.
Ensure that your CNC machine is both secure and balanced before lifting.
Do not tip the machine whilst lifting.
All lifting equipment must be certified as being suitable for the loads
involved.

3: Choosing a Site for your CNC Machine
Site your machine in a well ventilated room. If the Router is supplied for bench mounting it
should be sited on a bench of sturdy construction to take the weight of the machine and of a
height which enables comfortable operating and programming to take place.
If the Router is supplied with a Universal Machine Bench, the adjustable corner feet should
be wound down to contact the floor to help minimise noise and vibration.
Ideally, the user will operate the machine when standing at its front, with a clear view of
both the machine working area (through the transparent guard window) and the personal
computer being used as the controller unit (which should be angled towards the user), as
shown in the diagram below.
Sufficient room should also be provided for effective maintenance to be carried out around
the machine itself. In particular, leave enough space for removal of the large plate covering
the electronics at the right hand side of the cabinet. Positioning the PC on a movable
workstation may allow easier access to the various vents, connectors and switches on the
machine cabinet, when required.
Position any vacuum pumps used with the dust extraction at the rear, or under, the machine
table. The use of a centralised extraction system or, where possible locating the extraction
unit in a separate room, will help in noise reduction. If non-hazardous materials are being
cut, and the extraction unit is not employed, then noise level will be significantly reduced,
particularly if the cover on the side of the machine is secured in the closed position. Again,
if a vacuum pump is being used in conjunction with a vacuum work holding feature, remote
location would assist in noise reduction.
Do not place the machine in a position which allows any of the cabinet vents to be covered.
Ensure all cables, pipes and flexes are routed to avoid the possibility of users tripping over
them.
Allow space to remove the electrical

Dust extraction panel cover plate at the side of the
here. cabinet.
Dimensional Data.
Machine Length (left to
right ) 1200mm (47.2”).
Router on suitable
Machine height (top to Ensure table.
bottom 675mm (26.5”). that any
inlet/exhaust
Machine depth (front to
vents are not
back) 750mm (29.5”).
covered or
blocked.
Plan View showing Ideal Machine

Layout and Operating Positions. Computer desk, monitor,
keyboard and mouse angled
towards Operator.
Machine
Operator.

3: Removing Protective Coatings and Packaging
Once your Router has been sited and connected electrically, the Warning - x
protective coatings and transit packaging must be removed to
prepare the machine for running:
Potential risk of ignition /
1) The protective plastic sheeting on the guard door and window must explosion!
be removed prior to cleaning them with an antistatic cleaner. Do not use any aerosol
based or flammable
2) Tie-wraps may be used in the working area of the machine, to products to clean your
prevent movement of components during transit. Additional items CNC machine.
from your order may also be supplied packaged inside the working Carefully read and
area. follow any instructions
3) To gain entry to the working area of the machine, power must be or notices included with
supplied to the machine, in order to release the switch unit that cleaning products.
locks the safety guard door. Note that the switch unit will also
remain locked when the emergency stop button is fully pressed
in.
Warning - Aerosol based or flammable products must not be used
to clean your CNC machine. To avoid the potential risk of ignition
/ explosion, ensure that any trapped solvent vapours can exit fully
from any enclosed areas on the CNC machine. Wait at least 1
hour before attempting to operate the CNC machine.

4: Switching the Router On
Follow these instructions to switch on your Router:
Note - x 1) Check the Denford machine link cable is fitted securely between the
The safety guard cannot USB port socket on the machine controller PC and the USB socket,
be opened until the located on the right-hand panel of the router cabinet.
Router is powered up
to release the interlock 2) Check that all access panels are in position and securely fastened.
guard switch. 3) Check that all inlet/exhaust vents are clear from obstructions.
4) Check the flexible hose from your separate dust collection vacuum
system is securely fitted to the connection hole, located at the top of
Warning - x the left side viewing window.
5) Check that the guard door is fully closed.
Do not connect cables 6) Plug the router mains supply cable into an available power socket.
between any electrical Switch the power socket on.
hardware with the
mains power switched 7) The on/off power switch is located on the right-hand panel of the
on, since this could Router cabinet. To switch machine on depress the left-hand side of
seriously damage switch. The switch will illuminate when power is being supplied to
components inside your
CNC machine. the machine.
If the Router does not begin its power-up routine, switch off the
Warning - x mains power and check all connections and fuses.
8) Switch on the machine controller PC and start the CNC machine
control software.
Never attempt to access
the electronic hardware Establish a communication link between your machine controller and
systems of the machine PC.
with the mains power
switched ON. When the ‘found new hardware’ box appears install the driver for the
Note that hazardous USB connection (VR CNC milling cd must be in the CD Drive) - for
voltages can still exist
immediately after help please contact technical support 01484 728000.
switching off the power.
If the machine has When you start the motor for the very first time or if the motor
previously been has not been used for over a month, carry out a brief running
switched on, wait at
least 5 minutes before in routine with the following times:
attempting to open the 5 minutes at 50% of the max. speed
electrical panel cover
plate. 3 minutes at 80% of the max. speed
Many electronic 2 minutes at 100% of the max. speed
components are With every daily start, ALWAYS PREHEAT THE SPINDLE
sensitive to electrostatic
damage - ensure MOTOR following the indicated times:
components and/or 2 minutes at 50% of the max. speed
personnel are suitably
earthed to minimise 2 minutes at 80% of the max. speed
this risk. 1 minute at 100% of the max. speed
This routine allows the bearings and all rotating parts to
reach the ideal working temperature. It shall then reach the
maximum speed shown on the motor plate. If the spindle
motor is loaded cold, there is a reduction in the preload of the
bearings, and they will wear prematurely as a result.
4: Switching the Router Off
Warning - x Follow these instructions to switch off your Denford Router off:
1) Wait for the Router to fully complete any machining or
processing of any operational instructions.
Never attempt to access
the electronic hardware 2) Open the safety guard door and remove any finished parts
systems of the machine from the working area.
with the mains power
switched ON. 3) Close the safety guard door.
Note that hazardous 4) Close down the communication link between the CNC control
voltages can still exist software and the Router, then exit the CNC control software,
immediately after
as described in your separate CNC Control Software User’s
switching off the power.
Manual.
If the machine has
previously been 5) Shut down and switch off the machine controller personal
switched on, wait at computer.
least 5 minutes before
attempting to open the 6) Power down the Router by depressing the right-hand side
electrical panel cover of the red on/off mains power switch. The on/off switch is
plate. mounted on the right-hand cabinet panel, Note that cutting the
Many electronic machine power will trigger the closing of the interlock guard
components are switch. This will lock a closed safety guard door in position,
sensitive to electrostatic preventing access to the machine working area. The interlock
damage - ensure guard switch will automatically reopen when power is next
components and/or
personnel are suitably supplied to your Router.
earthed to minimise 7) Switch off the mains power socket.
this risk.
Warning - x
Depending on ancillary
equipment supplied with
machine there may be
more than one power
supply to the machine.
When isolating machine
always ensure that all
power sources have
been disconnected.

4: Homing the Machine Axes (Home Mode)
Note - x Immediately after establishing a communication link between the
CNC control software and the Router, all three axes of the CNC
The sequence of events
required to home the machine must be homed. The process is commonly referred to as
router will depend on the homing the machine, or datuming each of the three machine axes.
type of CNC machine When a communication link is first established between the router
control software being and the CNC machine control software, or when the CNC machine
used - please refer to
your separate CNC
“loses” position, the software will not know the true position of the
Machine Control machine head in relation to the three machine axes.
Software User’s Manual
for specific details.
Homing the CNC machine defines:
• The machine datum, by physically driving the machine head to a
fixed zero reference point.
• The constraints of three dimensional co-ordinate grid system
Note - x used for plotting any programmed movements, effectively the
working envelope of the CNC machine.
The CNC machine
control software Jog
and Auto Modes will not After homing the machine, the zero position of the three
become available until dimensional co-ordinate grid system is referred to as the machine
the machine has been datum. You can find the position of the machine datum by
configured by homing all switching the co-ordinate display in your CNC control software to
three machine axes. read Machine Co-ordinates. The position of the machine datum is
achieved when the X, Y and Z panels of the co-ordinate display all
read zero.
Note - x In addition to homing the CNC machine after it has first been
The machine datum switched on, we also recommend homing the CNC machine after
position is set by loading or configuring any offsets.
Denford and can never
be moved, since it
defines the physical
movement capability of
the CNC machine.

4: Manual Control - Axis Definitions (Jog)
Jog mode is used for manually controlling the CNC machine, moving the
three machine axes, changing tools, operating optional equipment and
configuring any offsets.
Axis Definitions.
X Axis - The X axis slides run at 90 degrees to the Y and Z axes, horizontally left
and right, when viewed from the front of the machine.
Minus (-) X movements run towards the left end of the machine and positive (+) X
movements run towards the right end of the machine.
Jog Keys to move axis - arrow keys left and right
Y Axis - The Y axis slides run at 90 degrees to the X and Z axes, horizontally
forwards and backwards, when viewed from the front of the machine.
Minus (-) Y movements run towards the front of the machine and positive (+) Y
movements run towards the back of the machine.
Jog Keys to move axis - arrow keys up and down
Z Axis - The Z axis slides runs at 90 degrees to the X and Y axes, vertically up and
down, when viewed from the front of the machine.
Minus (-) Z movements run down, towards the floor of the machine and positive (+) Z
movements run up, away from the floor of the machine.
Jog Keys to move axis -Page up and Page down

4: Machine Operators Panels
Note - x Spindle Speed and Feedrate Override

Feedrate override Controls.
changes will only be
The spindle speed and feedrate of the Router 2600 Pro can be
registered when an
actual spindle speed or manually overridden during a machining operation, using the
feedrate is being applied potentiometer controls fitted to the operators panel.
by the CNC control The spindle speed can be overridden between 50% and 120%.
software.
The feedrate can be overridden between 0% and 150%.
To increase the spindle speed or feedrate, rotate the appropriate
control clockwise.
To decrease the spindle speed or feedrate, rotate the appropriate
control counterclockwise.
The degree of adjustment applied to each value is displayed in the
CNC control software.
Warning - x
Mains Power Switch.
To supply power to the CNC machine, depress left-hand side
Depending on ancillary of the switch immediately above the power inlet socket. To cut
equipment supplied with power to the CNC machine, depress right-hand side of switch.
more than one power Do not cut the mains power when machining or processing of
supply to the machine. any operational instructions is taking place. Note that cutting
When isolating machine the machine power will trigger the closing of the interlock guard
always ensure that all switch. This will lock a closed safety guard door in position,
power sources have
been disconnected. preventing access to the machine working area. The interlock
guard switch will automatically reopen when power is next
supplied to your Router.
Note - x
Activating an emergency
Emergency Stop Button.
stop will also trigger the The emergency stop button is a circular red push button.
interlock guard switch. Pressing the emergency stop button has the effect of stopping
This will prevent a all axes and spindle movements immediately. To activate an
closed safety guard door emergency stop, press the button in fully until it clicks. The
from being opened.
emergency stop button will remain closed (continuing to cut
all power to the machine drives) until the release sequence is
performed. To release a closed emergency stop button, push and
turn the button clockwise until it springs back out, then wait 10
seconds for the machine systems to reset, unlocking the safety
guard door.

5: Performing a Tool Change
Warning - x Performing a Manually Requested Tool Change.
Before beginning a manual tool change operation, we recommend
you home the Y and Z machine axes and drive the X axis to roughly
Never open the safety
guard door and enter
the mid point on its axis. When the axes are in this position, the
the working area when maximum amount of free space will be available in the working
the spindle or machine area, allowing easier access to the tooling.
axes are moving.
Note - x Performing an Automatically Requested Tool

When two or more tools Change during the running of a CNC program.
are used in the same
CNC file:
On reading a tool change operation line in your CNC program,
Your new tool MUST be
refitted to router motor all three machine axes will move to their home positions, via an
and machine head intermediate point, if programmed.
in exactly the same
position used when
At this point, the software will pause the CNC program and a
originally configuring its message window will be displayed, prompting you to manually
Z tool offset value. change tools.
Always wait for the spindle and machine axes to stop moving,
before attempting to open the safety guard door.
Replace the current tool number with the tool number specified in
the software message window (the tool profiles allocated to each
tool number may be listed at the beginning of your CNC program).
Close the safety guard door and clear the software message
window to resume your machining.

Standard Tool Change System.
The tool change system, supplied as standard with your Router 2600 Pro, comprises
four elements:
i) The spindle motor with attached threaded shaft, configured to allow fitment of the
cutting tool and collet assembly.
ii) The collet and nut assembly - a tapered, tubular, split metal collet held inside the
locking nut, which threads directly onto the router motor threaded shaft. Different
sized collets and collet adaptors are available to allow use of cutting tools with
varying shank sizes.
iii) The cutting tool. (See recommendations below).
iv) Special Tooling - 2 off double ended spanners are supplied with the machine.
Bear in mind the following recommendations when choosing tools:
a) Only use fully sharpened tools, and make sure that they are securely
locked in the spindle.
b) Never use bent or damaged tools, chipped tools, or tools that are not
perfectly balanced.
c) Always make sure that the mating surfaces of tools are perfectly clean
and dent free before fitting the tool in the tool holder.
d) Never use tools at speeds in excess of that punched on them or specified
by their manufacturer.
e) Always ensure that the following essential requisites are met before using
any tool at high speed:
• The tool must be of compact, short, and lightweight design.
• The tool must be a precision instrument, and any inserts must be
held in to a high degree of security.
• The tool must be balanced and must mate symmetrically with
the tool holder.
• The cutting surfaces of the tool must be located near its centre
of rotation.
In general, the recommended balance rating for tools run at speeds over
6000 RPM is G2.5 (ISO 1940 standard).

‘B’ ‘A’
i) Spindle Motor
ii) Collet and Nut ‘A’ ‘B’

Assembly
iv) Double Ended Spanners
iii) Cutting Tool

5: Setting Tools in the Spindle Motor
Warning - x Tools required:

• 2 x Double Ended Spanners (supplied).
Caution.
Cutting tool may be Removing a Tool.
sharp.
If the cutting tool has
been recently used, it Position end ‘A’ of the first spanner around the locking nut on
may still be HOT. the end of the router motor shaft. Position end ‘B’ of the second
spanner around the locating fixture on the router motor spindle.
To loosen the locking nut, when directly viewing the end of the router
motor shaft, turn the spanner around the locking nut in an counter-
clockwise direction. Turn the spanner around the router motor shaft
in a clockwise direction.
Remove the nut and collet assembly, then remove the cutting tool.
Refitting a Tool.
Select the correct nut and collet assembly, according to the shank
size of your new cutting tool.
Hand thread the locking nut back onto the router motor shaft, then
insert the cutting tool into the nut and collet assembly. Position
end ‘A’ of the first spanner around the locking nut on the end of the
router motor shaft. Position end ‘B’ of the second spanner around
the locating fixture on the router motor spindle.
To tighten the locking nut, when directly viewing the end of the
router motor shaft, turn the spanner around the locking nut in a
clockwise direction. Turn the spanner around the router motor shaft
in an counter-clockwise direction.
Check that the cutting tool is secure before putting the machine
back in to operation.

6: Automatic Tool Change Option
The auto toolchange system requires a maintained pressure above 8
Bar (116PSI) to operate correctly. A 10 Bar compressor should be used
and be set to run when the air drops to 8 Bar.
The machine is fitted with a pressure switch that will prevent the
machine tool changing if the pressure falls too low.
The Toolchange system when fitted is recognised automatically by the

machine electronics so there are no parameters that have to be set.
You will however be prompted to confirm the position of the toolchanger
when manually changing tools and when running the machine in
automatic mode for the first time.
The toolchange motor can be fitted in 3 different positions on the Z axis

back plate to allow the machine Z travel to be available closer to the bed
or higher up for tall components.
The default position is the mid position.

Loading the tools into the tool rack for the first time.
In the VR Milling software add the tooling to the “Tool and Offset Editor” then fit the
tooling into the tool holders.
Take care to assemble the collet to the collet nut prior to fitting into the tool holder.
Ensure the correct collet size is used to match the tool shank.
In this case the library is loaded with the recommended router tooling (all with ¼”
shanks).

Ensure the Tool Rack is empty and there is not a tool in the spindle before starting to
load the tooling to the machine. If there is a tool in the spindle open the guard and
press the tool release button on the front of the machine to remove it.
Select one of the 5 tools in the “Tool and Offset Editor” that is not already selected,
say tool 5, highlight it then select the “Change Tool” option.
The machine will then move through the tool change procedure and try to pick
up tool number 5 (which is not present in the tool rack. On completion of the
tool change procedure the tool head will move to the final tool change position.
Open the guard and manually press the tool release button. Now offer up tool
5 to the spindle and then release the button.

T5 is now active as shown in the Control Panel.
Now fit the other tools in the correct pockets of the tool rack.
Select tool 1 in the “Tool and Offset Editor” then select the “Change Tool”
option.
The current tool will be placed in the rack and tool 1 will be picked up.
Once the tools are fitted in the tool rack you will need to set the tool length
offsets. To do this refer to the help section of the VR Milling Software.

Tool Rack Alignment.
The tool rack is aligned at the factory.
If for any reason you need to realign the rack use the following procedure:
Fit one of the toolholders in the spindle then jog the machine to the back left
corner of the bed until the axes reaches their limit. (Machine position X-600, Y0)
Lower the Z axis to Z-70 and align pocket 1 of the tool rack around the toolholder.
Lift the Z axis clear then travel to Y-120 and again lower the head to Z-70. Align
pocket 5 of the tool rack here and then secure the rack in position. Recheck
pocket 1 is still in position.
Note - the whole of the 600 x 400 working area is still available
when the ATC rack is in place. Therefore great care must be
taken when writing part programmes, or when jogging the
machine axes, to avoid collision with the tool rack and tooling.

7: Using the Work Clamp
Setting the Position of the Work Clamp.
Place the billet onto the machine table, so it is located correctly against the inside
edges of the datum plate. Set the work clamp in the open (unlocked) position. If you
have fitted the work clamp to the right end of the machine table, you must push the
handle back.
Slide the work clamp assembly along the machine table until the two flats on the
clamp plate are just touching the billet. Fully tighten the two hex bolts to firmly fix the
work clamp base plate in position on the machine table. At this stage, it should still be
possible to remove the billet.
To close (lock) the work clamp, pull the handle forwards. Press the end of the billet
down against the machine table, whilst locking the work clamp - this will prevent the
end of the billet from lifting. The handle should only need to be turned about one
quarter of a revolution before locking the billet firmly in position. If the billet can still
be moved, you must loosen the two hex bolts and reposition the work clamp base
plate so it is closer to the billet.
Press down
edge of
billet whilst
locking
clamp. Open clamp
(turn CCW).
Close clamp
(turn CW).
Now that the work clamp position has been set, the billet can be continually
withdrawn from the machine table, then replaced, always to the same position.
This is an advantage for jobs involving the repeat milling of pieces of work, such as a
small production run or a college class/group project.

7: Using the Work Clamp
The work clamp, when used in combination with the datum plate, is
a quick and versatile method of securing most pieces of work to the
machine table.
In the example shown below, a polystyrene billet is taped onto a
sheet of MDF (medium density fibreboard), with its front and left-
hand edges aligned with the front and left-hand edges of the MDF
- this front, left upper corner will be configured as the workpiece
datum for the machine offsets. The MDF is used as a sub-table - a
safety measure to prevent damage occurring to the machine table
itself, should a problem occur when milling.
Tape Tip - x Plastic workpiece (billet).

Use plastic type double Strips of double sided tape.
sided tape, which can
be removed from your
billet without tearing.
If your billet material
comes supplied with a
protective film, affix the Sub-table
tape to this film, then (eg. sheet of MDF).
simply tear off the film (Towards fr
ont of m achine table)
once machining has .
been completed. Avoid
The polystyrene/MDF block can then be added or removed from the
using tissue type double
sided tape, which is a machine table without having to reconfigure the machine offsets.
strip of tissue with a thin
coating of glue each
side - this type is very
difficult to remove from Sub-table
(eg. sheet of
your billet once it has MDF).
been machined. Work clamp.
Datum
plate.
Polystyrene
billet.
continued...

7: Fitting and Removing the Work Clamp
Removing the Work Clamp.
Using a 4mm allen (hex) key, loosen the two hex bolts clamping the work clamp
to the machine table. Do not completely remove the bolts at this stage, since this
will make removal of the individual tee nuts more difficult. Slide the entire work
clamp assembly to a free end of the machine table, release the tee nuts from their
respective channels and withdraw the work clamp assembly.
Fitting the Work Clamp.
Fit, align and clamp the datum plate. Loosely assemble the two hex bolts and tee
nuts through the two holes in the work clamp base plate. Move the work clamp
assembly to a free end of the machine table, then carefully align each tee nut with
the respective channels in the machine table and slide the clamp onto the table.
Before fully tightening the hex bolts, adjust the position of the clamp against your
chosen billet, as described on the next two pages.
Billet. Hex bolt.
Handle to open and

close work clamp.
Open clamp
(turn CCW).
Close clamp
(turn CW).
Work clamp
base plate.
To loosen bolts - turn

counter-clockwise
Hex bolt. (viewed from above).
T shaped To tighten bolts - turn
End view of machine table channel. clockwise (viewed
showing tee shaped channels. from above).

7: Fitting and Removing the Datum Plate
Removing the Datum Plate.
Using a 4mm allen (hex) key, loosen the two hex bolts clamping the datum plate
to the machine table. Do not completely remove the bolts at this stage, since this
will make removal of the individual tee nuts more difficult. Slide the entire datum
plate assembly to a free end of the machine table, release the tee nuts from their
respective channels and withdraw the datum plate assembly.
Fitting the Datum Plate.
Loosely assemble the two hex bolts and tee nuts on the datum plate. Four holes
are provided on the plate for the tee nut assemblies - we recommend using the
two outermost holes, as shown in the photograph below. Move the datum plate
assembly to a free end of the machine table, then carefully align each tee nut
with the respective channels in the machine table. Slide the assembly to the
approximate position required. Using a 4mm allen (hex) key, tighten each of the
hex bolts, by turning each bolt in a clockwise direction until they just begin to grip
the datum plate to the table surface. It must still be possible to move the datum
plate, since final adjustments will be required to align the plate exactly “square” with
respect to the edges of the machine table - exactly parallel to the direction of the X
and Y machine axes. After adjusting the position of the datum plate, fully tighten the
two hex bolts.
Hex bolt.
Datum plate Machine

(L-shaped work table.
T shaped locating bracket).
channel.
To loosen bolts - turn

counter-clockwise
(viewed from above). Hex bolt.
To tighten bolts - turn End view of machine table

clockwise (viewed showing tee shaped channels.
from above).

8: Large Format Vacuum Bed Option
The large format vacuum bed requires a dedicated 16A 240V supply that should be
protected by a Fuse or an MCB (Motor Circuit Breaker) C Type.
The pump is fitted in a standalone housing and is connected into the rear of the
machine.
The vacuum pump has an interlock to prevent it being turned off while the machine
is in Automatic Mode. This is to prevent the work becoming unclamped during a
program by inadvertently pressing the button during a cycle. Ensure the machine is
in Jog mode when starting or stopping the pump.
The system works by drawing air in through the surface of the vacuum bed and
requires some airflow to function correctly (so a complete seal should not be
applied).
A sacrifice board of MDF (from 6mm to 25mm thick) should be placed over the top
of the bed covering the entire surface. The airflow will be created sucking through
the MDF.
The workpiece is placed on top of the sacrifice board and is held down by the
suction through the sheet.
The vacuum bed is designed primarily for holding down large sheet material
allowing them to be cut through without damaging the bed below. As the clamping
force is created by the suction over the surface of the material, small parts will
break free.
Tall components or porous materials would have to be held by conventional
methods.
The Vacuum Bed is positioned in the X Axis with the edge of the MDF mounting
board 65mm from the edge of the aluminium T slotted bed whether or not the Auto
Tool Change Option is fitted. See illustration below.

Fitting and removing the Vacuum Bed
The vacuum bed will normally be supplied fitted to the machine. Simply
connect the flying lead from the back of the machine to a 16A 240V supply
and plug the vacuum pump into the socket at the back of the machine.
Connect the air pipe to the spigot on the pump and into the fitting at the rear
of the machine.
If other ancillary equipment is supplied with the machine such as a 4th Axis
Rotary Fixture, this may be fitted to the bed in place of the Vacuum Bed. In
this case the Vacuum Bed should be fitted to the machine when required
and positioned as shown on page 37.
With the machine also connected to the mains supply press the “Vacuum Pump”
button on the front of the machine and the vacuum pump will start to run.

To remove the vacuum bed, first pull the hoses off the fittings to the vacuum bed.
With the machine in the home position, remove the screws fastening down the
board to which the vacuum bed is mounted and remove the whole assembly. The
mounting board is to accommodate the difference between the hole centres in
the vacuum bed and the pitching of the T slots in the machine table, without the
need to drill holes into the table.
Unplug the Vacuum pump to prevent it being run without the bed attached.
The vacuum pump has an interlock to prevent it being turned off while the
machine is in Automatic Mode. This is to prevent the work becoming unclamped
during a program by inadvertently pressing the button during a cycle.

9: Planning Procedure for Maintenance Work
Warning - x When carrying out any maintenance, pay special attention to the
following items, ensuring safe and correct working procedures
in accordance with Health and Safety Regulations in your
Caution.
establishment:
Wear safety glasses and
a suitable respiratory • Before starting any maintenance work, define the task and
mask when cleaning the obtain the information relevant to carry out the maintenance.
machine. Also, define the time period needed to complete the task, to
obtain the correct tools and order any spare parts, if required.
Warning - x • During the maintenance work period, display a suitable notice
stating that the machine is under maintenance and should not
be used until the notice is removed.
Never open the safety
guard door and enter
• Safety must be a priority when carrying out any maintenance
the working area when work. Covers and safety guards that are removed during
the spindle or machine the maintenance work must be replaced after the task is
axes are moving. completed.
• All work must be carried out by suitably qualified personnel.
Warning - x
• Never attempt to access the electronic hardware systems of the
machine with the mains power switched ON.
Caution. • Hazardous voltages can still exist immediately after switching
If the cutting tool has off the power. If the machine has previously been switched on,
been recently used, it wait at least 5 minutes before attempting to open the electrical
may still be HOT.
panel access plate.
• When replacing electrical components, ensure the new parts
are of suitable replacement specification.
Warning - x
• All work completed on the machine, whether progressive, or
preventative, should be logged to ensure a complete service
Depending on ancillary record is available for future referral. We recommend the
equipment supplied with maintenance logs at the end of the maintenance section are
more than one power used to log any maintenance tasks undertaken.
supply to the machine. • When maintenance work has been completed, check that
When isolating machine the replaced or serviced parts work correctly, before allowing
always ensure that all general operation of the machine.
power sources have
been disconnected.

9: Maintenance Schedule
Every Day (and, if necessary between components)
• Clear dust from working area of machine and ensure that the
surfaces of the spindle, tool housing and tool are clean - do not
use compressed air.
Extra care must be exercised when changing from machining

MDF, hardwood, foam etc. to machining metal, to avoid any risk
of fire or explosion from ignition of dust particles by hot metal
chips. Also after machining metal, thoroughly clean areas around
leadscrews and guide rails to minimise risk of contamination from
chips.
Every Week
• Clean the machine thoroughly.
• Clean dust from router motor - see p32.
• Lubricate the slideways and leadscrews - see p33
• Check all exposed screws and nuts for tightness.
• Visually check door and window for signs of cracks or chips.
Any damage should be reported immediately to Denford
and a suitable replacement obtained without delay.
Door Part Number MRP/0402
Window Part Number MRC/0403
Every Two Months

• Check the condition of any electrical connections.
• Check and thoroughly clean all components of the tooling
system.
• Check all cables for kinks and breaks.
• Check door hinges for correct tension and adjust if necessary.
If, after fully hand tightening the centre screw of all
hinges with an appropriate tool, the door falls when
released from a position 15 degrees forward of vertical,
new hinges should be obtained and fitted without delay.
Denford part Number BI01229
Every Three Months

• Clean microswitches - see p32
• Check security of Spindle motor mounting bolts.

9: Maintenance of the Spindle Motor
Maintenance of the Fimec spindle motor is limited to:-
i. Regularly (at least once a day if tools are changed
frequently) checking that the surfaces of the spindle,
tool housing and tool are clean.
ii. Occasionally cleaning the grill of the cooling fan with a
soft brush or vacuum (never use compressed air) and
removing any objects blocking the air ways.
iii. Occasionally checking the security of the fixing of the
motor to the machine.
iv. The bearings are lubricated for life and do not require
greasing.
For any maintenance beyond the above, the motor should be returned to
Denford or an authorised Fimec agent.
9: Cleaning the Microswitches

The X,Y Z axis all have microswitches
Using a soft bristled brush, carefully clean dust and debris away from the
microswitch, to an area where it can be removed using a vacuum cleaner.
X Axis Switch Y Axis Switch located Z Axis Switch located

located top rear corner top front corner
behind rear column of crossbeam of head slide

9: Lubrication of the slideways and leadscrews
Use of Swansil Lubricant on Denford Routing Machines
1. Clean down machine with brush and vacuum - do not use compressed air.
2. Position the Machine in mid-travel.
3. Open the guard.
4. Isolate machine from power supply.
5. Spray each lead screw and guide rail with a 2-3 second burst.
6. Leave 2-3 minutes for silicone to dry before operating the machine.
Item 1 to carried out daily or between components.
Items 2 – 6 to be carried out weekly.
Always adhere to general instructions and warnings on Swansil

can.
For full health and safety information visit http://www.swantek.com/html/msds/136.htm
Do not spray into confined areas.
Any excessive over spray to be dried off with a dry, clean, lint-free cloth before operating
the machine.

9: Maintenance Log
Date of Name of personnel Details of
maintenance carrying out the maintenance work
work. maintenance. completed.

9: Maintenance Log
Date of Name of personnel Details of
maintenance carrying out the maintenance work
work. maintenance. completed.

10: Technical Support
Denford Limited provides unlimited telephone and e-mail Technical Support
on this CNC machine to registered users. On-site visits by our engineers may
be chargeable. Please refer to the information held in your separate Warranty
pack, for specific details.
Before contacting Denford for support, please read your hardware and software
manuals and check the Denford websites for support.
Internet (access technical support and FAQ sections):
www.denfordata.com/bb
When you request support, please be at your CNC machine, with your hardware
and software documentation to hand. To minimise delay, please be prepared to
provide the following information:
• CNC Machine Serial Number (from the machine ID panel).

• Registered user's name / company name.
• The CNC machine control software name and version number (from the
“Help/About” menu option).
• The wording of any error messages that appear on your computer screen, if
applicable.
• A list of the steps that were taken to lead up to the problem.
• A list of any maintenance work that has been carried out on the CNC
machine.
Contact Details:
Denford Limited,
Armytage Road, Brighouse, West Yorkshire, HD6 1QF, UK.
Telephone: 01484 728000
Fax: 01484 728100
Technical Support: Monday to Friday 8.30am - 4.30pm GMT
For international dialling: +44 and remove first 0 in each city code.

11: Specification of the Router 2600 Pro
Safety Features:
• Manual operation, totally enclosed, interlocked, safety guard door.
• Emergency stop button.
• Toolpath graphics to verify part programs prior to machining.
Mechanical Details:
• Travel X axis 600mm (23.6”).
• Travel Y axis 400mm (15.7”).
• Travel Z axis 110mm (4.3”).
Dimensions:
• Machine width 1200mm (47.2”).
• Machine height 675mm (26.6”).
• Machine depth - door closed 750mm (29.5”).
Weights:
• Machine weight 160 KG (350 lb).
Electrical Details:
• Mains supply required:
220/240Volts, 50Hz, 8 Amps.
• Spindle motor: 1.0 kW
• Spindle Speeds: 0 - 24,000RPM.
• Axis stepper motors
Performance:
• Rapid traverse rate up to 5000 mm/min (197 in./min)
• Max Feed traverse rate up to 5000 mm/min (197 in./min)

11: EC Declaration of Conformity
for Machines prior to 29.12.09
EC Declaration of Conformity
The responsible person Mr P T Harkness

Business Name Denford Limited
Address Brighouse
West Yorkshire
United Kingdom
Declares that the machinery described:
1. Make Denford Limited
2. Model Router 2600
3. Serial Number
Conforms to the following The Machinery Directive 98/37/EC
Directives The EMC Directive 89/336/EEC
The LVD Directive 73/23/EEC
Also the following standards
(where applicable) ………………………………
And complies with the relevant
health and safety requirements ………………………………
Signature of responsible person

………………………………
Position Senior Design Engineer
Signed at Brighouse
West Yorkshire
United Kingdom

11: EC Declaration of Conformity
for Machines after 29.12.09
EC Declaration of Conformity
Mr P T Harkness
The responsible person and
person authorised to compile the
Technical File
Business Name Denford Limited
Address Armytage Road

Brighouse
West Yorkshire
HD6 1QF
United Kingdom
Declares that the machinery described:
1. Make Denford Limited
2. Model Router 2600 Pro
3. Serial Number
Fulfils the relevant provisions of
the following Directives
Machinery Directive 2006/42/EC
Low Voltage Directive (LVD) 2006/95/EC
EMC Directive (2004/108/EC).
Also the following standards
(where applicable)
EN 953 1997 + A1 2009: Safety of machinery – Guards. General requirements for the design and
construction of fixed and movable guards.
EN 954-1 1997: Safety of machinery - Control systems - Part 1 General principles for design.
EN 60204-1 2006: Safety of Machinery - Electrical-equipment of machines Part 1 General requirements.
EN ISO 12100-1 2003: Safety of machinery. Basic concepts, general principles for design - Part 1 Basic
terminology, methodology.
EN ISO 12100-2 : Safety of machinery. Basic concepts, general principles for design - Part 2: Technical
principles.
EN ISO 13732-1 2006: Ergonomics of the thermal environment. Methods for the assessment of human
responses to contact with surfaces - Part 1: Hot surfaces.
EN ISO 13850 2008: Safety of machinery - Emergency stop -Principles for design.
BS EN ISO 14121-1 2007: Safety of machinery - Risk assessment Part 1 Principles.
EN 55011 2007: Limits and methods of radio interference characteristics of industrial, scientific and medical
equipment. Conducted Emissions.
EN 55011 2007: Limits and methods of radio interference characteristics of industrial, scientific and medical
equipment. Radiated Emissions.
EN 61000-4-2: 1995 +A1 +A2 2001: Testing and Measurement Techniques; Electrostatic Discharge
immunity test.
EN 61000-4-3: 2002 +A1 + A2 2005: Electromagnetic Compatibility – Basic Immunity Standard. Radiated
radio frequency electromagnetic field immunity test.
EN 61000-4-4 2004: Testing and measurement techniques. Electrical fast burst/transient immunity test.
Signature of responsible person ………………………………
Position Senior Design Engineer
Signed at Denford Ltd., Armytage Road, Brighouse
Date ………………………………

10: Router 2600 Series Noise Level Test Results

!
" #

$ $ % &

& " ' (

$ )

* ' &
* + + , ! & - . * /
E B F G
A H ; 8 = > ; @ 9 :
I : @ ;
B > > 9 : ; 8 9 C
D
; = ; @ 9 :
7 8 9 : ; 9 7 < = > ? @ : A
>
* 0 - 0 0 1 2
! 2 +

3
* - . * /
* -
! 4 2 4 5 4 ) 4 &
! 6 " ' 4 5 4 ) 4 ) 4 &
!
$ ! + 6 )

' + &
" ' ! ! 6 " '
6 6
' ! ! 6 +
+

12: Glossary
BILLET ................................. A small, usually rectangular, bar of wood or metal in an intermediate stage of
manufacture.
CAD ......................................Computer Aided Design - the use of a wide range of computer based tools that assist
engineers, architects and other design professionals in their design of “real world”
objects.
CAM......................................Computer Aided Manufacture - software that is capable of creating tool cutter paths in
a number of different axes for different CNC systems. Usually taking the design input
from CAD system.
CNC.......................................Computer Numerical Control - a computerised system of hardware and software,
which controls the movement of a machine tool.
DRIVE ................................. The controller unit for a disk system.
DRY RUN ........................... An operation used to test how a CNC program will function without driving the
machine itself.
DWELL ............................... A programmed time delay.
EDIT ................................... The mode used for altering the content of a CNC program via the Desktop Tutor or
qwerty keyboard.
END OF BLOCK SIGNAL ... The symbol or indicator ( ; )that defines the end of a block of data. The equivalent of
the PC [return] key.
ERROR................................. The deviation of an attained value from a desired value.
G-CODE ............................. The programming language understood by the machine controller.
FEEDRATE ......................... The rate, in mm/min or in/min at which the cutting tool is advanced into the workpiece.
For milling and drilling, the feedrate applies to the reference point on the end of the
axis of the tool.
FILE .................................... An arrangement of instructions or information, usually referring to work or control
settings.
FORMAT ............................. The pattern or way that data is organised.
FNC .................................... FANUC Miller file, extension ".fnc". Contains G and M codes describing the machine
and cutting operations.
G CODE ............................. A preparatory code function in a CNC program that determines the control mode.
HARDWARE ....................... Equipment such as the machine tool, the controller, or the computer.
HOME ................................. Operation to send the axes of the CNC machine to their extreme limits of movement.
Defines the co-ordinate based grid system of the CNC machine. Commonly referred
to as homing the machine, or sending the machine to its home position.
INCREMENTAL .................. Incremental programming uses co-ordinate movements that are related from the
previous programmed position. Signs are used to indicate the direction of movement.
INPUT ................................. The transfer of external information (data) into a control system.
INTERFACE ....................... The medium through which the control/computer directs the machine tool.
Router 2600 Pro Operator Manual

K L M N O P
12: Glossary
JOG CONTROL.................... Manual movement mode for the machine axes, using very small pre-defined
movements, called jog steps. One stepped movement is applied per movement using
the machine offset facility. key/button press.
M CODE ............................. A miscellaneous code function in a CNC program used to indicate an auxiliary
function (ie, coolant on, tool change etc.).
MACHINE DATUM ............. A fixed zero reference point set by the machine manufacturer. The machine datum is
used to define the co-ordinate based grid system of the CNC machine. All machining
co-ordinates originate from this point. However, this point can be temporarily moved
MACHINE OFFSET .............. The workpiece offset file used with VR and real CNC machines.
MDI ..................................... Manual Data Input - A method used for manually inserting data into the control system
(ie, Desktop Tutor, qwerty keyboard etc.).
MODAL ............................... Modal codes entered into the controller by a CNC program are retained until changed
by a code from the same modal group or cancelled.
NC ...................................... Numerical control.
OFFSET ............................. Combination of two types of file, the workpiece offset and the tool offset. Used to
describe the workpiece datum, a zero reference used on the CNC machine to ensure
machining occurs in the correct place on the billet. Offsets are used to shift parts of
the three dimensional co-ordinate based grid system, used by the CNC machine.
PART DATUM ..................... Used as a zero reference point in a CNC file. All machining co-ordinates originate
from this point.
PART PROGRAM ................. A list of coded instructions which describes how the designed part, or component, will
be manufactured. The part program is also referred to as the CNC file, program, or G
and M code program.
PC ....................................... Personal computer.
POST PROCESSOR............ A file or setting that contains instructions for a CAM system, detailing how to create
CNC code that can be understood by a particular CNC system (e.g. VR CNC Milling).
PROGRAM ......................... A systematic arrangements of instructions or information to suit a piece of equipment.
RAPID TRAVERSE............... Fast movement of the cutting tool through the 3 machine axes between cutting
settings.
REFERENCE POINTS ......... The machine has 3 reference points used in setting the limits of movement for its
slides (axes).
REMOVEABLE MEDIA.........A computerised storage medium that is not permanently attached to the system, e.g.
Floppy Disk, Flash Memory Card, USB Memory Key, CD/DVD disc.
ROUTER MOTOR ................ The removable cutting head (motor). Also referred to as the machine head.
RPM...................................... Revolutions per minute (rev/min) - a measure of spindle speed.
SLIDES ................................. The 3 machine axes - see axis.
SPINDLE SPEED ............... The rate of rotation (velocity) of the machine head / cutting tool, measured in RPM.
SOFTWARE ....................... Programs, tool lists, sequence of instructions etc...

Q R S T U V
12: Glossary
TOOL OFFSET ................... When machining, allowances must be made for the size of tools being used, since
they all differ in length. The tool offset is the amount the Z value must be moved (or
offset), so that all the different cutting tool tips used line up with each other, so they
can all be used by one CNC file. See OFFSET.
TRAVERSE ........................ Movement of the cutting tool through the 3 machine axes between cutting settings.
TXT ..................................... Standard Windows text only file, extension ".txt".
WORK (WORKPIECE) ....... The actual material being machined. The work is sometimes referred to as the billet
or stock.
WORKPIECE DATUM ........ Used as a zero reference point on the real billet. All machining co-ordinates originate
from this point, when offset files are used.
WORKPIECE OFFSET ........ A file containing X, Y and Z values that can shift the entire three dimensional co-
ordinate based grid system, used by the CNC machine. See OFFSET.
WORD ................................ A combination of a letter address and digits, used in a CNC program (ie, G42, M04
etc.).
VIRTUAL REALITY............... A fully interactive, three dimensional, computer based simulation of a real world object
or event.
Z TOOL OFFSET ................ See Tool Offset

W X Y Z [ \
13: Notes
Use this page to make a note of any parts of the software you have changed or configured,
for example, common tooling set-ups, machine parameters, changes to installation paths or
passwords etc.

] ^ _ ` a b
Contact Details :
Denford Limited,
Armytage Road, Brighouse,
West Yorkshire, HD6 1QF,
UK.
For General Enquiries :

Telephone: 01484 728000
Fax: 01484 728100
E-mail: info@denford.co.uk
For Sales Enquiries :

Telephone: 01484 728000
Fax: 01484 728100
E-mail: sales@denford.co.uk
For Customer Services and Technical Support :

For Free Online Technical Support visit Denford’s Technical Forum at :
www.denfordata.com/bb
Telephone: 01484 728000
Fax: 01484 728100
Technical Support: Monday to Friday 8.30am - 4.30pm GMT
For international dialling from outside the UK: Add “44” to the
number and remove the first “0” from each city code.
Disclaimer :
Please note that due to nature of hardware and software developments, the
specifications and features of this product can change without notice. The
information contained in this guide is correct at the date of printing only - September
2010. If in doubt, please refer to your order and delivery invoices. No liability can
be accepted by Denford Limited for loss, damage or injury caused by any errors
in, or omissions from, the information supplied in this manual. Denford Limited
reserves the right to alter any specifications and documentation without prior notice.
No part of this manual or its accompanying documents may be reproduced or
transmitted in any form or by any means, electronic or mechanical, for any purpose,
without the express written permission of Denford Limited. All brands and products
are trademarks or registered trademarks of their respective companies. Copyright
Denford Limited - Version 08.09.10. All rights reserved.
Language :
This manual is written using European English.
Questions and Comments :

Any questions and comments regarding this guide should be referred to the
following e-mail address: customerservices@denford.co.uk
Alternatively, telephone Denford Customer Services on 01484 728000 and ask to
speak to a member of our Technical Authoring Team.
http://www.denford.co.uk

c d e f g g

Router 2600 Pro Operator Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Router 2600 Pro Operator Manual

Uploaded by

Copyright:

Available Formats

Router 2600 Pro

Telephone: General Enquiries 01484 728000

Technical Support: Visit Denford Technical Forum at www.denfordata.com/bb

Telephone Denford Customer Services: 01484 728000

Router 2600 Pro Operator Manual Page 2

Router 2600 Pro Operator Manual Page 3

Router 2600 Pro Operator Manual Page 4

Router 2600 Pro Operator Manual Page 5

Portable Appliance Testing.

Router 2600 Pro Operator Manual Page 6

If equipment is permanently connected to the fixed installation, e.g. by a flex outlet or

• Cables located so as to avoid damage

Before carrying out the following tests ensure the machine is

Earth continuity Test (Class 1 equipment)

The test should be carried out at 25A for a period of 5 – 10 Seconds

Router 2600 Pro Operator Manual Page 7

A qualified electrical engineer should make the following

The insulation resistance test can now be carried out

Router 2600 Pro Operator Manual Page 8

Router 2600 Pro Operator Manual Page 9

Router 2600 Pro Operator Manual Page 10

Router 2600 Pro Operator Manual Page 11

The emergency stop button is

Router 2600 Pro Operator Manual Page 13

system. screw screw position

Router 2600 Pro Operator Manual Page 14

General Dust Safety Precautions.

Denford do not advise manual lifting of this machine, however if no other

Router 2600 Pro Operator Manual Page 16

Allow space to remove the electrical

Plan View showing Ideal Machine

Router 2600 Pro Operator Manual Page 17

Router 2600 Pro Operator Manual Page 18

Router 2600 Pro Operator Manual Page 20

Router 2600 Pro Operator Manual Page 21

Router 2600 Pro Operator Manual Page 22

Note - x Spindle Speed and Feedrate Override

Router 2600 Pro Operator Manual Page 23

Note - x Performing an Automatically Requested Tool

Router 2600 Pro Operator Manual Page 24

Bear in mind the following recommendations when choosing tools:

Router 2600 Pro Operator Manual Page 25

ii) Collet and Nut ‘A’ ‘B’

iii) Cutting Tool

Router 2600 Pro Operator Manual Page 26

Warning - x Tools required:

Router 2600 Pro Operator Manual Page 27

The Toolchange system when fitted is recognised automatically by the

The toolchange motor can be fitted in 3 different positions on the Z axis

Router 2600 Pro Operator Manual Page 28

Router 2600 Pro Operator Manual Page 29

Router 2600 Pro Operator Manual Page 30

T5 is now active as shown in the Control Panel.

Router 2600 Pro Operator Manual Page 31

The tool rack is aligned at the factory.

Router 2600 Pro Operator Manual Page 32

Router 2600 Pro Operator Manual Page 33

Tape Tip - x Plastic workpiece (billet).

Router 2600 Pro Operator Manual Page 34

Billet. Hex bolt.

Handle to open and

To loosen bolts - turn

Router 2600 Pro Operator Manual Page 35

Datum plate Machine

& " ' (

! 6 " ' 4 5 4 ) 4 ) 4 &

" ' ! ! 6 " '